Honda-CBR150R-Service-Manual-English

CHAARRGGIINNGG SYSTTEEMM

• This modeell comes with a maintenance free (i.e. sealeedd andd electroollyyttee filled) type battery.

BAATlTTERY TESTTIINNGG
Refer to the instructions inn the Operatioonn Manuuaall for the recommmeennddeedd battery tester for details about the battery
testing.
The recommmeennddeedd battery tester puts a "loadd"" on the battery so that the actual batteerryy conditionn of the loadd cann bee
measured.

Reeccommeenndeedd battery tester BM221100 or BAATTTTEERRYYMAATTEE or equivalent

CAUUTTIIOONN::
For batteryy charrggiinngg,,doo not exceed the charggiinggcur"reennt and time ssppeecciiffieddon the batteerryy.. Ussiinggexcessssiivveecurrent or
extendding the charggiingg time may damage the battery.

SPECIFFIICCAATTIIOONNSS

Battery ITEEMM SPECIIFFIICCAATTIIOONNSS
Alternator
Capacity 12V- 5AA hh
Current leakaaggee 0.1 mAmmaax
Specific gravity Fully charged
13.0 --1133..2 V
Needdss chargingg
Charggiinngg current Normal Below 12.3 V

Quick 0..55AAx 5--1100 hh
Capacity
Charggiinngg coil resissttaannccee(20O°0CC/6/86°8F")F) 2.5AAxx 1 hh
Lightinngg coil resistance (20O°oCC/6/688°"FF)) 1555WI/ 5,00000 min-I' (rppmm))

0. 22--11..o0n0

0.1.1--00.88R0

17-22 http://mototh.com

CHAARRGGIINNGG SYSTEM

TROUBLESHOOTING

Battery is damaggeedd or weak

RReemmoovvee tthhee bbaatttteerryy ((ppaaggee 1177--44').. - -IInnccoorrrreecctt _ . FFaauullttyy bbaatttteerryy

Checkk the batteryy conditionn usingg the reccoomm--

mennddeedd battery testeerr..

RECOMMENDED BAATTTERY TESSTTEERR:
BM-21100 or BAATlTERY MATTEE or equivalent

I -,--- IInnccoorrrreecctt _ Disconnect the regulator/hrectifier 4P connec-
tor and recheck the battery current leakage.
Correct

iI

Insttaallll the batteryy (paaggee 177--44))..

Checkk the battery current leakaaggee (Leaakk test:

pagee 177--77))..

SPECIFIEEDD CURRENT LEAAKKAAGGEE::0..11 rmnA max Incorrreecctt Correct

I L i

Correct Faulty regulator/hrectifier

~ - Shorted wire harnesss
Faulty ignitionn switch

- .CChheecckk tthhee aalltteerrnnaattoorr cchhaarrggiinngg ccooiill ((ppaaggee 1177--77)).. r---- Incorrect _ . FFaauullttyy c,.hbaarrggiinngg ccooilil

- t-STAANNDDAARRDD: 0.2 -11..00 QR (2O0°oCC//6688°OFF))
I
-f--- Correct _ . Faulty battery
Correct

~1

Measure andd recordd the batteerryy voltage
using aa ddiiggiittaall mrnuullttiimmeetteerr(paaggee 17--44))..

Start the engine.
Measure the charging vvoollttaaggee ((paaggee 177--55))..
Compare the measurements to result of the
followinngg calculation.

MEASSUURREEDD BAATTTTEERRYY VOLTAGE <c -Incorreecctt - '* Openn circuit inn relatteedd wire
MEASSUURREEDD CHARGING VOLTAAGGEE <c 15.5 V
-* Looossee or poor contaccttss of relatteedd terminal
II
• Shortteedd wire harness
Incorreecctt

~1

Performm the regulator rectifier wire harneessss
inspection (paggee 177--88))..

Correct

~

* Faulty reguullaattoorr/hreeccttiiffiieerr

http://mototh.com 17-33

CHAARRGGIINNGG SYSTEEMM

BATTERY BATl'ERY COVER

REMOVAALL

NOOTTEE::

Always turn the ignition switch OFFF before removing or
installing the battery.
Disconnect the battery negaattiivvee cablee first,. then positive
cable from the battery.

Remmoovvee the driver seat (paggee 2-21)..
Remove the trim clip andd openn the batterryy coveerr..

Remmoovvee the bolt and disconnect the battery negative s BOLT

H(-1 cablee.. NEEGGAATTIIVVEE H(-1

Remoovvee the positive terminal cover. CABBLLEE
Remoovvee the bolt andd disconnect the battery positive
((++) cIablee..

Remmoovvee the battery out of the battery casee..

INSTAALLLLAATTIIOONN CABLE

Inssttaalll the battery into the case. 6
Coat the battery terminal with cleaann grease.
Plaaccee the battery into the cassee andd connect the battery
positivvee (+) cable to the battery., then (c;onnect the negative
H(-1ccaabbllee..
Inssttaalll the posittiivvee terminal cover.

NNOOTTEE::
Pullll the comver over the positive terminal.

INSPECCTTIIOONN

Measure the battery voltage using a commercially avail-
able digitaall multimeter.

VOOLLTTAAGGEE: (20°CC/688°0FF))::

Fuullllyy cchhaarrggeedd: 113.0 -- 13.2 V

Undeerr cchhaarrggeedd: Beeloow 1122..33 V

17-44 http://mototh.com

CHARGINNGG SYSTEM

BATTIEERRYY CHARGIINNGG I

,!f.i.!d...."

• TThhee battery gives off explosive gasseess; keepp sparks,
flames and cigarettes awayy.. Provide adequate

vennttiillaattiioonn wheenn chaarrggiinngg..
• TTuurrnnpoweerr OONN//OFF at the chaarrggeerr,, not at thee battery

terminnaallss..

Remove the battery (paggee 17-41).

Connect the charger positive ((++)Icable to the battery
positive (+) terminal.
Connect the charger negative ((--1) cable to the battery
negativee ((--1) terminal.

CHARGGIINNGG CURRRREENNTT//TTIlMMEE
Standdaarrdd::
Quuiicckk:

CAUTION:
• QQuuiicckk--cchhaarrggiinnggshould only be done in an emmeerrggeennccyy;;

slow charging is prefeer"reedd..
• For batteryy chargingg,, do not exceed the charging

current and timee specified on the battery. Using
excessive current or extending the charging time
may dammaaggee thee battery.

CHARGINNGG SYSTEM INSPECTION

CHARGIINNGG VOLTAGEE INSPECCTTIIOONN

'M;';"'""• If the enginee must be runningg to ddoo some woorrkk,, make

sure thee area is wweell-ventilated. Never run the engine

in an enclosed areeaa.. TThhee exhausst contains poisonous

caarrbboonnmonoxide gas that may cauussee'loss ofccoonnsciouss--
ness and may 'lead to deaath.

NOTFE:

BBe sure the battery is inn good condition before perform-
ing this test.

http://mototh.com ~

17-5

CHAARRGGIINNGG SYSTTEEMM

CHARGGIINNGG OUTTPPUUTT::
Warmm upp the engine to normaall operating temperaattuurree..
Stopp the engine, andd connect the mrnuulltimeter as shown.

CAUTIONN:

• Too prevent sshhoorrt, make absolutelyy ceertain whichh are
the possitive and neeggaattiveeteermmiinnaalss or cabbllee..

• Do not discoonnnneeccttthe battery or any cable in the chhaarrgg--
ing ssysstem without first sswwitching off the ignition
sswwitch. Failure to follow thiss precaution can dammaggee
the tesstteerr or eleeccttrriiccaall cCoommpDoonneenntsts. .

With the headlight onn Hii beam, restarrtt the engine.
Measuurree the voltage on the multimeter when the engine
runnss at 5,000 miinn--1' (rpmm))..

Standard:

Meassuurreedd batteerryy voltage (pagee 177--44)) << Measurreedd
charginngg voltage ((SSeeeeabove) < 1155.5 V aat '5,000 rprmn-'

The battery iss normaal if voltage readdss the reguullaatteedd volt-
age onn the mrnuultirmneter.

NOTTEE:: ~~~

~~

The speeedd at whichh voltage starts to risee cannot bee checckkeedd

as iittvaries with the temperature andd loads of the genera-

tor.

LIGHTTIINNGG OUTTPPUUTT::

NOOTTEE::
Measuurree the voltage with the headlight wire conneccttoorrss
connected.

Connecctt the voltmeter positive (+) probe to the headlight

66PP connector Bluueeterminal, andd negaattiivvee H(4probe to the

Greeeenn wire terminal.
Start the engine andd light switch is "HW" positionn and the
dimmer switch is ·"Hi"" position,, andd reaadd the voltage..

-REGGUULLAATTEEDDVOLTAGE: 1122..11-1133..11 Vat 5,000 mrniinn-' (rpmrn))

17-66 http://mototh.com

CURRREENNTT LEAKKAAGGEE INSPECCTTIIOONN CHAARRGGIINNGG SYSTEEMM

Turn the ignition switch off and disconnect the battery E
negaattiivvee (--1) cablee from the battery.
Connect the ammeter positive ((+t))probe to the ground
cable andd the ammeter negativee H(-) probe to the battery
negaattiivvee H(4terminal.
With the ignition switch off, check for current leakage.

NOTTEE::
* Whenn measuurriinngg current using a tester, set it to a high

range, and then brinngg the rangee down to ann appropri-
ate level. Current flow higher than the ranggee selected
may blow oout the fuse in the testeerr..
While measuring current, do notturn the ignition switchh
ON.. A sudden surge of current may blow oout the fuse
inn the testerr..

SPECCIIFFIIEEDD CURRENT LEAKAGE: 0.11 mA max

IIf current leakaaggee exceeds the specified value, a shorted
circuit iss likely.
Loccaatteethe short by disconneeccttiinnggconnectiioonnss one by one
andd measuring the current.

ALTERNATOR INSPECTIIOONN

NOTE:
IItt iss not necessssaarryy to remove the stator coil to make this
test.

Releeaasseethe alternator 4P connector from the clamp of the
frame.

Disconnect the alternator 4P connector.

Checckk the resisttaannccee betweeenn following terminals.

STTAANNDDAARRDD:
-Charggiinngg coil (White - Ground)
II -0.2 -11..00 nR (at 2O0°oCC/6/688°"FF))
I -White - Ground

-Lighhttiinngg coil (Yellow - Ground)

I -Yellow - Ground II 0.11 -- 0.8 nR (at 20°C/68°"F)

Reppllaaccee the alternator stator if readings are far beyondd
the standard.
Refer to page 9-2 for stator removaall..

http://mototh.com 17-7

CHARGING SYSTEM

REGULATOORR/REECCTTIFIER

SYSTEM INSPECTION

Remove the rear cowl (page 22-2).

Disconnect the regulator/rectifier 4P connector, and check
it for loooose contact or corroded terminals.

If the regulated voltage reading (see page 17-4) is out ooff
the speciffiiccaattiioonn,, measure the voltage between connec-
torr terminals (wire harness side) as follows:

Item Terminal SpecifliCca8tion
Battery Battery voltage should
charging line Red (++))and resister
Charginngg coil Standardd resistance;
line ground (H-1
1 k -- 20 kCn2 (20°C/S68°"F)
Lightingg coil White and
line ground Standarrdd resistance;

Ground line Yellow and 10 k -- 200 kkQR (2200°"CC!6W8°FFI)
Green
Continuity should exist
G:rzrt:neden and

ground

If all components of the charging systemm are normall and

there are no lloooosse connectioonnss at the regulator/hrectifier

connectors, replace the regulator/reccttiiffieerr unit.

REMOVVAALL//IINNSSTTAALLLIAATTIIOONN

Remmoovvee the regulatorr//rreeccttiiffiieerr unit mounting bolt..
Disconnect the connector andd remoovvee the regulaattoorr/hrecti-
fier unit.

Innssttaalll the regulator/reccttiiffieerr unit iinn the reverse order of
remoovvaall.

1177--88 http://mototh.com

IGNNIITTIIOONN SYSTEM

SYSTEMM DIAGRAAMM

IGNNITTIIOONN SWWITTCCHH

IGNITION COIL
IGNITION CONTROL MODULE (lCM)

<l7To Tachometer ...---+:-1 IGNNIITTIIOONN FNUSSEE
SWIITTCCHH 220MA
BI -0'-:-0------ RR
IG & - % & $ -BATTERY
~ 12VSAH

IGNITION IGNITON B81I::BBllaacckk
COIL CONTROL BBuu:BBlluuee
MOODDUULLEE((IICCMM)) Y:Y:Yeellilooww
SPARK R:Red
PLUG IGNNIITTIIOONN G ::GGreenn
PWULLSSEE
-- -- GENNEERRAATTOORR

--

188--00 http://mototh.com

18. IGNITIOONN SYSTEM

SYSTEMM DIAGRAM 18-0 IGNITION COIL 18-5
SERVICE INFORMAATTIIOONN 188--11 IGNITION CONTROL MODULEE (lICMM)) 18-5
TROUBBLLEESSHHOOOOTTIINNGG 18-22 IGNITION TIMING 18-66
IGNITTIIOONN SYSTEEMM INSPPEECCTTIIOONN 18--33

SERVICE INFORRMMAATTIIOONN

GENERAL

P!iU@";

Hif thhe enggiinnee must be runningg to do some wwoorrkk, make sure thhe area is well venttiillaatteedd.. Never run thhe enginne in an

enclossed areeaa.. Thhee exhaust connttains poisonous carbonn monnooxxiidde gas that mayy causse losss off connsscciioouussnneessss and may
lead too ddeatthh..

CAAUUTTIIOONN::
Somme electrriiccaall ccoommppoonneennttss mmay be ddammaggedd iiff ttermmiinnalss or ccoonnnneeccttoorrss arre ccoonnnneecctteedd oor ddiissccoonnnneecctteedd wwhhiillee tthhee
ignition switch is ON and ccuurrrrent is pmresent.

When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 18-3.
The ignition timing does not normally need to be adjusted since the Ignition Control Module (ICM) is factory preset.
The Ignition Control Module (lCM) may be damaged if dropped. Also if the connector is disconnected when current
is flowing, the excessive voltage may damage the module. Always turn off the ignition switch before servicing.
A faulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure
the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.

SPECIFICATIONS

ITEEMM SPECIFICAATTIIOONNSS

Spark plugg NGK DEENNSSO0

I Standard CCRR88EE U24ESR --NN
II Oppttioonnaall
CR9SEE U27EESSRR -- N

Spark plugg gap 0.77 -- 0.88 mmm (0.002288-- 0.032 inn))

Ignniittiioonn coiill peakk voltaggee 100 V minimumm

Iggnniittiioonn ppuullssee generator peeaakk voltaggee 0.7 V mminnimmuumm

Ignnition timing 1122°" BBTTDDCC at 1,.40000 ±k 10000 mmiinn"-' (rppmm))

TORRQQUUEE VAALLUUEE

Timinngg holee cap 6 N·.m (0.6 kgf·.m, 4.33 Ibf·4ftt))

TOOLS

Ilmriee diagnoossttiicc tester (mooddeell 625) or 07HHGGJJ -00002200110000 with
Peak voltaggee adaptoor Commeercially available digital multimeter (impeddaannccee 100 MnR//DDCCVV
minimmuumm))

http://mototh.com 188--11

IGNITION SYSTEM

TROUBLESHOOTING

. IInns~peecctt the following before diagnosinnggthe system.
-FaFualtuylty spark plug
-LoLoosoese spark plug cap or spark plug wiree connection
-WWataetrer got into the spark plug cap (leakiinnggthe ignition ccoil sseeccoonndary vvooltage)
If there is no spark at cylinnder, temporarily exchange the ignition ccoil wwith tthhe ootthheerr good oone aand perform tthhee spark
ttee~stt.. If there iis spark, the exchanged ignition coil is faulty.

Noo spark at plug

Ignition coil Unussuuaall con d i t i oonn Probabblleecause ((CChhe~ckk in numericcaall order)
primary Low peak voltage
voltage 1. The multimeter impedance is too low.

No peak voltage 2. Crankingg speed is too low.
• Battery under charged.

3. The sampling timme off the tester and measured pulse were
not synchronized (Systemm is normaal if measureeddvoltage is
over the standardd voltage at least ones))..

4.. Poorly connectedd connector or an open circuit in ignition
system.

5.. Faulty ignition coil (Measuurreethe peak voltage).

-6. Faulttyv ICMM (inn case when above No..11- 5 are normmaall))..

11.. Incorrecct peak voltage adaptor connectionss.
2. Faulty ignition switchh..
3. Loosee or poor connectedd ICMM conneccttoorr..

4. An open circuit or loose connneeccttiioonnin Greennwire.
5.. Open circuit or poor connection in groundd wire of the ICMM.

6. Faulty peak voltage adaptor, or lImrie tester.
7. Faulty ignition pulsee generator (meaassuurreethe peak volt-

agee))..
8. Faulty ICMM (inncase when above No..11- 77 are normmaall))..

Peaakk voltage is normmaall,, but no 11.. Faulty spark plugg or leakkiinngg ignition coil secondary
spark jumps at pluugg.. current.

Ilagnittiioonn pDuullssee Loww pDeeaakk vooltaaggee 2. Faulty ignitiioonn coil.

I -generator 11.. The muultimetteerr impedaannccee is too low; below 10 MQN/DDCVV..
' 2. Craannkkiinngg speedd is too low
33. The sammpplingg timingg of the tester andd meeaassuurreedd pulssee
No peak voltaggee
were not synchronnizeedd (sysstteemm is normmaall if meeaassuurreedd
voltage is over the standaarrdd voltage at least onccee))..
4. Fauullttyy ignition pulssee generaatoor (iinn case when above No.11

-- 3 are noorrmmaall))..

11.. Fauulty peak voltage adaptor or Ilrmnrriiee tester.
2. Fauulty ignitionn pulssee geneerraattoorr..

1188--22 http://mototh.com

IGNNITTIOONN SYSTEEMM

IGNITIOONN SYSTEM INSPEECCTTIIOONN I DDIGGITTAALL MMUULLTTIIMMEETTEERR

-NOOTTEE:
If there is no spark at plug, check all connections for

loossee or pooor connttaacctt beefooree mmeeaassuurriinnggpeeaakk voltage.
UUssee commmmeerrcciiaallllyy available digital mmuultimeter with ann
impeeddaannccee of 1100 MMOn//DDCV mminimumm..
Thee displayy valuuee differs deppeennddiinngg uponn the internaall

imppeeddaannccee of the mmuultimetteerr..
If ussinngg Ilmrie diaggnnoossttiicc tester (mooddeell 625), follow the
mmaannuuffaaccturer's inssttrruuccttiioonnss..

I PPEEAAKK VOOLTTAAGGEE ADAPTORR

Connnneecct the peak voltaaggee adaptor to the digitaal muulltimm--
eter, or use the Ilmriee diagnostic tester.

TOOOLLSS::

Ilmriee diagnnoossttiic tester (mooddeell 6255)) or
-07HHGGJJ - 0002200110000 wwiithh
PPeeaakkvvoollttaaggeeaaddaappttoorr

CCoommmmeerrcciiaalllyyavaaiillaabblleedigitall multimeteerr (impedaannccee

1100MWW/lDCV minimumm))

IGNITIIOONN COIL PRIMARY PEAK VOLTAGEE

NOTE:
*• Check all system connections beforee inspection. If the

systemm is disconnected, incorreecctt peak voltage might
be measured.
Check cylinder commpprreessssiioonn andd check that the spark
plugg is installedd correctly.

Disconnneecctt the spark pluugg capp from the spark plug (paggee
33--66))..
Remmoovveethe fuel tank (paggee 5-33))..
Conneecct a good known spark plugg to spark plug cap and
ground the spark plug to the cylinder as done in a spark
test.

http://mototh.com 18-3

IGNITTIIOONN SYSTEM

With the ignition coil primary wirree connected, connect tthhee
peak voltage adaptor or lImrie diagnostic tester probe to
the ignition coil primary wiirre terminal and ground..

CONNECTION:

Blackl/Yellow terminal (++))-BBooddyy ground ((-1-)

Turn the ignition switch ""OON""..

Crank the engine with the starteerr motor and read ignition
coil primary peak voltage.

PEAKK VOLTTAAGGEE: 1000 V minimum

'Sf'. . "".Avoid touchinngg the sppaarrlke plug and tester probes to pre-

vent electriicc shock.

If the peak voltage is abnormaall,, check an open circuit or
poorly connected connectors inn BlaacckW/Yeelllow wire.
If not defects are found inn the harness, refer to the trou-
bleshooting chart on page 18-22..

Instaallll the removedd partss inn the reversee order of removal.

IGNITTIIOONN PULSSEE GENERAATTOORR
PEAAKK VOLTAAGGEE

NOTTEE:
Chheecckkccyylliinnddeerr comprreessssiioonn andd checkkthattthe spark plug
iss installedd correctlyv.

Remmoovvee the fuel tank (pagee 5--33))..

Disconnect the 66PP connneeccttoorr fromm thee ICMM.
Connnneeccttthe peeaakkvoltaaggee adaptor or Ilmriiee diagnotic tester
probeess too thee connector termiinnaallss ooftthhe wire harnneessss side.

TOOLS:

Ilmriee diagnostic tester I(mmooddeell662255)) or
-077HHGGJJ - 00002200110000 wwiitthh
Peeaakk voltage adaptor

Commmeerrcciiaallly avaaiillaabbllee digiittaall multimeter (immppeeddaannccee

1100MaNJDCVV minniimmuumm))

COONNNNEECCTTIIOONN::
Blue/Yellow terminal ((++))-GGrereeenn ((-))

CCrraannkk thhee eennggiinnee wiitthh starter mmootor aanndd rreeaadd thhee ppeeaakk
vvooltage.

PPEEAAKK VVOOLLTTAAGGEE:: 00.7 V mmiinniimmuumm

,I,U,,"'''

AAvvoid ttoouucchhiinnggtthhee ssppaarrlek ppllug and tteesstter pprroobbeess ttoopprre-
vveenntt elleccttrriiccsshhoocckk..

1188--44 http://mototh.com

IGNITION SYSTEMM

If the peaakk voltage measured at lIeCMM connector iss abnor--
mal, measure the peak voltage at the ignition pulsee gen-
erator 44PP connector.

Disconnect the ignittiioonn pulse generator 44PP connector andd
connect the tester probeess to the terminal (Bluuee/NYellow and

Ground).
Inn the same manner as at the lIeCMMconnector, measure the
peakk voltage andd compare it to the voltage measured at
the lIeCMM connector.

-• If the peak voltage measured at the lIeCMM is abnormal

andd the one measuurreedd at the ignition pulsee generatorr
iss normal, the wire harness hass ann openn circuit or loose
connection.
* If bothh peakkvoltages measure are abnormal, check eacchh
item inn the troubleshooting chart. IIf all itemss aree nor--
mal, the ignitiioonn pulsee generator is faulty. Seee section
9 for ignition pulsee generator replacement.

Inssttaalll the removveedd parts inn the reverse order of removal.

IGNNITIONN COIL 18-5

REMMOOVVAALL/AINNSSTTAALLLLAATTIOIONN

Remoovvee the fuel tank (paaggee 55--33))..
Disconnect the spark plug cap fromm the spark plug (paaggee
33--66)1. ,
Disconnect the primary wire connector.
Remmoovvee the two bolts andd ignition coil.
Installlaattiioonn is inn the reverse order of remoovvaall..

IGNNITIONN CCOONNTTRROOLLMODULE (lICCMM))

REPPLLAACCEEMMEENNTT

Remoovvee the fuel tank (paggee 55--33)1. ,
Disconnect the lIeCMM 66PP connector.
Remoovvee the lIeCMM from the rubber brackkeett..
Insttaallll the lIeCMM inn the reverse order of removvaall..

http://mototh.com

IGNITION SYSTEM

SYSTEM INSPECTIONN

Disconnect the ICM 6P connector., and check it for loose
contact or corroded terminals.

Turn the ignitionn switch ON.

Measure the voltage betweenn connector terminals (wire

harness side) as follloowwss:'

1 Item 1 Terminnall I Sopecification 1

Battery line Black and Battery voltage
Green shou lId exist

Ground line Green and Continuity
ground should exist

Instaallll the removedd parts inn the reverse order of removal.

IGNITIOONN TIMINGG

I,;"",;

• «Iftthhe enngginee must be running to doo ssoome woorkk,, mmake
ssuure the area is weelll-veennttiillaatteedd.. Never run the ,emngine
in an enclosed areeaa..

• Thheeexhaust coonnttaainsspoissonouss carboonnmmoonnooxxiiddeegas
that may cause losss of ccoonsscciousnesss and may lead to
ddeeaatthh..

NOOTTEE::
RReeaaddthe instruction for timiinngg lighhtt operaattiinngg.

Warrmm uupp thee engine.
Stopp the enggiinnee anndd reemmoovvee thee timing hoollee capp.

Coonnnneecctt the timmiinngg light too thee spark plluugg wire.

Starrtt the enggiinnee anndd lleet iitt idle..

*IIDDLLEE SSPPEEEEDD: 11,40000 ± 110000mmiinn--I' ((rrppmm))

1188--66 http://mototh.com

IGNITIONN SYSTEM

The ignition timing is correct if the "FF"" mark aligns with
the index notcchh onn the left crankcasee coveerr..

Apply oil to the O-ring and install and tighten the timing
hole cap to the specifiedd torque.

TOORRQQUUEE: 66 N.'m (0.6 kkggff·m. 4.33 Ibff·4ftl)

http://mototh.com 18-7

EELLEECCTTRRIICC STAARRTTEERR

SSYYSSTTEEMM DIAGRRAAMM

CLUTCH/NEUTRAL DIODE

STARTER MOTOR

STARTER
MOTOR

STARTER

a: a: IGNITION FUSE SWITCH

~ I __~__>= I SWIT~H lOA 3P Bl
(O-_Bl__--o-_-....oY- :«3---1?f--_____

0Il.-NEUTRAL

INDICATOR

DIODE SWITCH 8B1I::BBllaadcke
YY::YYeellilooww
G :Grreeeenn
R ::RReed
W :WWhhItbe
Lg :LUight! Greeen

19-0 http://mototh.com

19., ELECTRICC STARTER

SSYYSSTTEEMM DDIIAAGGRRAAMM 1199--00 STAARRTTEERR MMOOTOR 1199--44
SSEERRVVIICCEE IINNFFOORRMMAATTIIOONN 1199--11 STAARRTTEERR RRELLAAYY SWWIITTCCHH 1199--1100
TTRROOUUBBLLEESSHHOOOOTTIINNGG 1199--22 CLLUUTTCCH/NEUTRALL DIIOODDEE 1199--1111

SERVIICCEE IINNFFOORMMATIIO0NN

GENERAALL

lilia.uP"';

AAlways ttuurrnn the iggnniittiioonn sswwiittcchh OOFFFF bbeeffoorree sseerrvviicciinngg the starter moottoorr.. TThhee motor couulldd sudddeennlyy start,, cauussinngg
sseerriioouussinnjjuurryy..

• TThhee starter mmoottoorr ccaann bbee sseerrvviicceedd withh thhee eennggiinnee inn thee framee.
WWhheenn cchheecckkiinngg thee sstaarrtteerrssyyssteemm,, aallwwaayyssfollow thee ssteppss inn the troubbleesshhoooottiinngg flow chart (ppaaggee 19-2).
A wweeak bbaatttteerryy mmaayy bbee uunnaabbllee to tuurrnn the starter mmootor qquuiicckkllyy enough, or supply adeqquuaattee ignniittiioonn current.
If thee ccuurrrreenntt iss kkeepptt flowwiinngg throuugghh thee sstarter mmoottor to turnn iit while the engginee iss not crankkingg over, the starter
mmoottor mmaayy bbee ddaammaaggeedd..

• RReeffeerr to paaggee 9-44 for starter cluuttcchh servicing.
• RReeffeerrto secctionn 2200 for followwiinngg commppoonneennttss:

--Ignnition swwiittcchh

-StSatratertrer swwiittcchh
-NeNueturatrlal swwiittcchh
-ClCultucthch swwiittcchh

SPECIFICATION STANDDAARRDD Unit: mm (in)

l ITEEMM 10.00 --1100..0055((00..339933-- 00..339966)) JSERVIICCEE LIMIT

I Starter motor bruusshh lennggtthh 33..55 ((00..1144) ) I

http://mototh.com 19-11

ELECTRIICC STARTER

~

TROUBLESHOOTINGG

Starter motor will not turn

Check for a blown main fuse (20AA)) or sub-fuussee (10AA))..
•* Check that the battery is fully charged and inn good condition (secttiioonn 17))..

Check for loose or poorly connectteedd battery Abnormal -_---.t Poorly connectedd battery cable
cable, and open circuit inn battery cable.. * Open circuit in battery cable

Normall Abnormal -_ . Poorly connected terminals or connectors

I -- Abnormal _ .* Poorly connecteedd starter motor cable
•* Open circuit inn starter motor cable
Check for loose or poorly connected starter
relay switch terminals and connectors. -r--- Clicckkss - Connect the starter motor terminal

II directly to the battery positivee terminal.

Normmaall (Beeccaauussee a large amount of current

J flows, do not use a thin wire.)

Check for loose or poorly connected starter I II
motor cable, andd openn circuit inn starter
motor cable. Starter motor turns Starter motor
does not turn
II jI
1
Normmaall
Faulty starter motor
!

With the ignition switch ON, push the starter
switcchh andd checckk for a ·"Click"" sound fromm
the starter relay switch.

Noo clicks

Cheecckk the starter relayy swiittcchh ground linnee Abnormal • Looossee or disconnneecctteedd starter motor
(ppaaggee 1199--1100)]..
cable
NNoorrmmaall
--• Fauullttyy starter relay switchh
j
_ . Fauullttyy neutrall switch

Faulty diode

Faulty clutchh switchh

Looossee or poor connectoorr contact
* Opeenn circuit inn wire harness

TToo paaggee 199--33

1199--22 http://mototh.com

ELECTRIC STARTER

Froomm pagee 19-22 Abnormal --_4_ •* Faulty ignition switch
Blownn fuse
l Faulty starter switch
Loossee or poor connector contact
Check the starter relay voltage (page 19-10). * Openn circuit inn wire harness

Normaal --Abnormal __ • Faulty starter relayy switch

Check the starter relay switch operation
(paaggee 19--1100)).,

Starter motor turns slowly

--•* Weak battery
Poorlyy conneecctteedd battery cable
Poorlyy conneecctteedd starter motor cable
Faulty starter motor

Starter motor turns, but engine does not turnn
•* Faulty starter clutchh (seeccttiioonn 9))

-Starter relayy switch ·"Clicckkss"·,, but engine does not turn over

• Cranksshhaafftt does not turn due to engine problem
•* Faulty starter reduction gear (secttiioonn 9))

http://mototh.com 199.-.33

ELECTRIICC STARTERR O-RIN G
FRON'T COVEI'!
STARTER MOTOR

REMOOVVAALL

P¥hMilii

AAlwways tuurrnn tthhee iiggnniitionn switcchh OFF before servicing thhe
ssttarter mmoottoorr.. Thhee motor could suddenly start, caussiinngg
sserious innjiuurryv..
Remmoovvee the under cowll (paggee 2--33))..
Remmoovvee the rubber capp..
Rammoovvee the terminaall nut and starter motor cable.
Remmoovvee the two mounting bolts and ground cablee..
Remmoovvee the starter motor from the left crankcase.

DIlSAASSSSEEMMBBLLYY//IINNSSPPEECCTTION

Remmoovvee the oO--rriinngg..
Remmoovvee the starter motor case bolts, and O-rings.

Remmoovvee the front coveerr,, lock washer andd seaall ring.

IOCt: WASHEFI

Remmoovvee the shims.

19-4 http://mototh.com

Remmoovvee the rear cover, shims and seaall ring. REAR COVER ELECTRIC STARTER

Remove the armature from the motor case. SEAL RING

NOTE::
Reeccoorrdd the locatioonn and number of shims.

Checckk the needle bearingg and dust seaall inn the front cover DUST SlEAL NEEDt£ BEARI G
for wear or damage.

FFiO TeO . R

Checkk the commutator barss of the armature for discolora- ARMATURE
tion.

NOTE::
DDoo not ussee emery or sand paper on the commutator.

co 1MutATOR AflS

Check for continuity betweenn pairs of commutator bars.
Therree should bee continuity.

http://mototh.com 19-5

ELECTRIC STARTER

Checkk for continuity betweeeenn eacchh commutator bar and
the armatuurree shaft.
Theree should bee noo continuity.

Check for continuity between the insulated brush and cable
terminal.
There should bee continuity.

Checckk for continuity betweeenn the cable terminal and rear
coveerr..
There should bee noo continuity.

Remmoovvee the following: O-RING SHIM S
--nnuut t
-wwaasshheersrs d
-sshhi mi ms s
W A S H EAS
--OO-r-irningg
--bruusshh holder assembly

Remmoovvee the brushess fromm the brusshh holder.
Measure the bruusshh length.

SERVICE LLIIMMIITT::3.5 mm m (0.1144 inn))

199--66 http://mototh.com

ASSEMBLY ELECTTRRIICC STARTER

REAR COVER

TERMINAL 'A\&k!y LOCK
WASHER
ARMATURE

\

NEEDLE
BEARING

/ \ FRONNTT COVER

BOLT O-RIINNGG

Inssttaallllthe bruusshheess inttoo the bruusshh holldderr.

m~us S

BftUS HO LI)~Fl

Inssttaallll the brruusshh holdder assembly intoo thhe rearr covver by C-RING BRUSH HOLDEFl
aligniinngg thhe tab of the hollddeerr with the groooovvee of the rear
covveerr..
Inssttaallll thhe new O-riinngg..

http://mototh.com 19-77

ELECTTRRIICC STARTERR SHI ,S Nul

Inssttaalll the shims, washers and nut.

Inssttaalll the armature into the motor casee while holding the REAA COVEA WA.~H RS
armatuurree tightly to keeepp the magnet of the case from pull-
ingg the armature against it.. ,....,... SEAL RING

CAAUUTION::
Thhee coil may be ddamaged if thhe magnet pulls thhe arma-
tuurree agaainst thhee ccaassee..

Inssttaalllthe same number of washers and shims in the same
locatioonnss as notedd during disassembly.

NOTEE::
The number of shims are different individually.

Inssttaalll a new seaall ring.
Inssttaalllthe rear cover by aligning the brushh holder tab with
the motor cassee groove.

Inssttaalll the lock washer to the front cover.

RONT COliER. lOCKWM AS
FRON COVE
Inssttaalll the shims and a new seall ring.
Inssttaalll the front coverr..

199--88 http://mototh.com

ELECTRRIICC STARTER

Align the index lines on the front cover and motor casee..
Insttaallll the new O-ringgss onto the motor casee boltss..
Insttaalll and tighten the motor case bolts.

INSTALLLAATTIIOONN

Coat a new O-rinngg with oil and install it into the starter
motor groove.

~I """""7I11I O-RING

Insttaallll the starter motor into the crankccaassee..
Insttaallll the ground cable and mounting bolt,. then tighten
the bolts securely.
Instaallll the starter motor cable and terminal nut onto the
motor terminal and tighten the nut securely.
Instaallll the rubber cap over the motor terminal securely.
Instaallll the under cowl (page 2--33))

http://mototh.com 19-99

ELECTRRIICC STARTER STARTER RELAY SWITCH

STARTER RELAY SWITCH

INSPEECCTTIIOONN

NOTE:
Before checking the starter relayy switch, checckk for battery
condition.

Removvee the driver seat (paggee 2-2). RELAYY SWITCCHH 4P CONNEECCTTOORR

Shift the transmission into neutraall..
Turnn the ignition switch ONN andd depress the starter switchh
button..

The coil is normal if the starter relaayy switch clicks.

If you don't hear the switch "CLICK", inspect the relay
switch using the procedure below.

GROUUNNDD LINNEE
Disconnect the starter relayy switch 4P connector.
Checkkfor continuity betwweeeennthe Greenn//RReeddwire (grouunndd
linee)) andd ground.

If theree is continuity when the transmission is inn neutrall
or when the clutcchh iss disengaged, the ground circuit iss
normal ((IInnneutral, there iss a slight resistance due to the
diode).

STAARRTTEERR REELLAAYYVOLTTAAGGEE
Connect the starter relay switch 4P connector.
Shift the transmissioonn into neutraall..

Measure the voltage betwweeeennthe Yellow/Redd ((++I) wire and

ground at the starter relay switch 4P connector.

If the battery voltage appears only when the starter switchh
is pressseedd with the ignition switch ON, it is normal.

STARTER RELAY SWITCCHH I

OPERAATTIIOONN CHECKK 8
Disconnect the starter relay switchh 4P connector andd
cabless..
Connect a fully charged 122 V battery positivvee wire to the
relaayy switch Yelloww//RReedd wire terminal andd negative wire
to the Green/Redd wire terminal.

There should bee continuity betwweeeenn the larggee terminals
while the batteryy is connected, andd no continuity when
the batterryy is disconnected.

199--1100 http://mototh.com

ELECTTRRIICC STARTER

CLUTCH/NEUTRALL DIODE

INSPEECCTTIIOONN

Remoovvee thhe rearr cowwll
(paggee 2--33)). .

Remoovvee thhe diooddee.

Checkk for conttiinnuuiittyy betwweeenn the dioodde termiinnaallss.. DIODE
When there isscoonnttiinnuuiittyy,,a smmallll resiissttaanncceevaluuee will regg-
isstteerr..

If there iss conttiinnuuiittyy inn onne dirreeccttiioonn,,the diooddee iss noorrmmaall..

_1o '---_1... 0

http://mototh.com 199--1111

LIGHTS/METERS/SWITCHES

SYSTEM LOCATION

IGNITION SWITCH

CLUTCH SWITCH

TURN SIGNAL RELAY

NEUTRAL SWITCH

2200--00 http://mototh.com

20. LIGHTS/MEETTEERRSS//SSWWIITTCCHES

SYSTEEMM DIAGGRRAAMM 20-0 FUELL METEERW/FUELL UNIT 200--1111
SERVVICCEE INFORRMMAATTIIOONN 200--11 HOORRNN 20-133
TROUUBBLLEESSHHOOOOTTIINNGG 200--22 TURN SIGNAL RELLAAYY 20-133
BBUULLBB REPLLAACCEEMMEENNTT 200--33 COOOOLLIINNGG FAANN MMOOTTOORR SWWIITTCCHH 200--1144
COMMBBIINNAATTIIOONN METER 20-5 COOLLAANNTT TEMPERAATTUURREE GAUGE/
IGNITION SWITCCHH 20-77 THERMMOOSSEENNSSOORR 20-155
HAANNDLLEBBAARR SWWITTCCHHEESS 20-88 CLLUUTTCCHH SWITTCCHH 20-16
BBRRAAKKEE LLIGGHHTT SWWITTCCHH 20-88 TACHHOOMMEETTEERR 20-177
NEUTRAALL INDICAATTOORR//SSWWIITTCCHH 20-99

SERVICE INFORRMMAATTIIOONN

GENERAALL

Ussee an electric heating element to heat thhe water/coolant mixturre for the thermossensor innssppeeccttiioonn.. KKeep all
fllammmmaabbllee mmatterriiaallss awayy fromm the electricc heating elemmeenntt.. Wear proottecttiivvee clootthhiinngg,, insuulated gloovves and eye
prootteeccttiioonn..

Check the battery condition beforee performing any inspeeccttiioonn that requireess proper battery voltage.

A continuity test cann bee made with the switches installeedd on the motorccyyccllee..

The followinngg color codes usedd aree indiccaatteedd throughout this section.

Buu:: Blluuee GG:: Greeeenn Lbb:: Light Bluee R: Reedd

BI:: Blaacckk Grr:: Grayy 00:: Oraannggee W: White

Br: Broowwnn YY: Yellow

SPECIFICCAATTIIOONNSS

IITTEEMM I SSPPEECCIIFFIICCAATTIIOONNSS I
Headlight (Hi/low beamm))
Bulbs Brakeh/taaiilllightt 122VV - l 818/11188WW ~x 22
Licceennssee light
Fussee Froonntt turnn signnaall light 1122 Vv --1100!/55WWXx 2
Thermmoosseennssoorr Rear turn signaall light
resistaannccee Instrument light 1122VV-- 55WW
Turn signal indicator
High-bbeeaamm indicator 122vV--110Ww xx22
Neuuttrraall indicator 122vV--110wWxx2
Main 122 vV--11..77Ww x 4
Sub
50°C (112222°°FF)) 1 2 VV--11..77WW
120°C (224488°°FF))
12 VV--11..77WW

12VV--11..77WW

200A

100AAxx 2

113333.9 --117788..99 0C2
14..99--117..33R0

http://mototh.com 200--1I

LIGHTS/METERS/SWITCHES

TROUBLESHOOTING

Heaaddlliigght do not come on or bulb is freqquennttllyy burned
when the engine is startedd

-- Faulty lighting and/or dimmer switch
Faulty bulb
Faulty alternator lighting coil (section 17)

-* Faulty regulatorh/rectifieer (sectiioonn 17))
Loose or poorly connecteedd connector

Headdllight beamm does not shift when Hi-Looswitch is opp--
erated

-- Burned bulbb
Faulty dimmerr switch
Loose or poorly connected connectorr

2200-2 http://mototh.com

LIGGHHTTSS//MMEETTEERRSS//SSWWIITTCCHHEES

BULBB REPLACCEEMMEENNTT

HHEEAADDLLIIGGHHTT DUST

RReemmoovvee the dust covveerr..
Whhile puusshhiinngg in, turrnn thee buullbb sockkeett couunntteerrcclloocckkwwiissee
too remmoovvee iitt..
Remmoovveethe headlight bullbb andd replace it with a new one.

Inssttaalll the headlight bulbb inn the reverse order of remmoovvaall..

NNOnTTEF:. "TOP" MARRKK

Inssttaalllthe dust cover tightly against the headlight housinngg
with the "TOPP"" mark facingn up.

FROONNTT TURN SIGNAL LIGHHTT SOCKET

Removvee the screws and upper cowl lid (page 2-55)).. BULB
Turn the bulb socket counterclockkwwiissee and remove itt.. REAR
Removvee the bulb and replace it with a new one. COMBINATION LIGH-IT
Installattiioonn is in the reverse order of removal.
I
REAR TURN SIGNAL AND TAIL/BRAKE
LIGHHTT AND LICENSEE LIGHT ~.rv-~--'

Remoovvee the passengerr seat (pagee 2-2). 2200--33
Disconnect the rear combination light 6P connector.
Removvee the screw and rear combination meter.

C

http://mototh.com

LIGHTS/METERS/SWITCHES

REEAARR TURN SIGNAL LIGHT

Turrnn the bulb socket counterccloocckkwwiissee and removvee it..
Reemmoovvee the turn signaall bulbb and replacee it with a new
onnee..

TAIlL/lBBRRAAKKEE LIGHT SOCKEETT
Turrnn the bulbb socket countercllocckkwwiissee andd removvee itt..

While pushing iinn,, turn the bulbb counterclockwissee to

remmoovvee it
Remmoovvee the tail/lbrake light bulbb and replacee it with a new
onee..

LICEENNSSEE LIGHT
Turn the bulbb socket counterccllloocckkwwiissee and removvee iitt..
Remmoovvee the bulbb and replace it with a new one.
InssttaallilDotioonn is inn the reverse order of remoovvaall..

20-4 http://mototh.com

COMBBIINAATTIIOONN METER LIGHTS/METERS/SWITCHES

REMOVAL F~ON T PA EL.

Disassemble the upper cowl (paggee 2-5).

BUULLBB REPLACCEEMMEENNTT

Pulll the indicator and instrument bulbb socket out of the
combination meter.
Removee the bulb from the socket and replace it with a
new one.

DISASSEMBLLYY

Remove the six screws and speedometerr front panel.

Remove the indicator and instrument light bulbss.. SUO HARN ESS
Remove the screws and combination meter sub harness
from the rear panel.

Remoovvee the speedometer,, tachometer, fuel meter and
coolant temperature gauge.

G

TI G SCflEWS

http://mototh.com 20-5

LIGHTS/METERS/SWITCHEESS : /SUB
ASSEEMMBBLLY
/ HARNESS
SPEEDOMETER /
FUEL METER

COOLAANNTT TEMMPPEERRAATTUURREEGAAUUGGEE

Asssemblle the speedometer inn the revverrssee order of
diissasssseemmbbllyy..

NOTTEE::
• Roouutteethhe sub harrnneessssass shoowwnn..

INSSTTAALLLLAATTIIOONN

Assssemmbbllee thhee uuppppeerr ccoowwll (paggee 2-4)..

NOOTTEE::
Roouuttee tthhee ccoommbbiinnaattiioonn mmetterr wiirree anndd ccaabbllee pprrooppeerrllyy
(ppaaggee 1--1177))..

200-6 http://mototh.com

LIGHTTSS/MMEETTEERRSS//SSWWIITTCCHHEESS

IGNNIITTIIOONNSWITCCHH

INSSPPEECCTTIIOONN

RReemmoovveethhee fuueell tank ((ppaaggee55--33)1..

DDiissccoonnnneeccttthhee iiggnniittiioonnsswwiittcchh 2PP ccoonnnneeccttoorr..

CChheecckkfor ccoonntinuity bbeettwweeeennthee wwiree terrmmiinnaallss of thhee igg--
nniittiioonn sswwiittcchh ccoonnnneecctor iinn eeaacchh sswwiittcchh ppoossiittiioonn..
CCoonnttiinnuuiittyysshhoouulldd eexxiisstt bbeettwweeeennthhee ccoolloorr ccooddeeddwwiirreess aass
follows:

1 -----IGGNNIITTIIOONNSWWITTCCHH H01
BAT ,...
ON ,...
OFF ~

LOCK B

COLOR R

REMOVALLIAINNSSTTAALLLLAATTIOIONN

Disconnnneecctt the ignitioonn switcchh 2P connector.

Remmoovvee the two bolts and ignition switchh..
Instaallllthe ignition switch inn the reverse order of remoovvaall..

http://mototh.com 20-7

LLIIGGHHTTSS//MMEETTEERRSS//SSWWIITTCCHHEESS

HANDLEBBAARR SWITCHES

Remoovvee the fuell tank (pagee 5-33))..

Disconnect the right handlebar switch 3P connector.

Disconnect the left handlebar switch 9P and 2P (Blaacckk))
connector.

Checkkfor continuity between the wire terminalss oftthe han-
dlebar switchh connector.
Continuity should exist betweeenn the color coded wire ter-
minals as follows:

LLIIGGHHTTIINNGG SWITTCCHH DIMMER SWITCCHH

~ C1 (HL) TL ~ (HL) Lo Hi LIGHTINNGG SWITCCHH DIMMER SWITTCCHH
Lo 0-~ Bu
OFF
(N)
(N) - - -.rI
H , Br ,Hi W
COLOR V
COLOR

TURNN SIGNAL SWITCCHH ElHORRNNSWITTCCHH TURN SIGNAL \
SWITTCCHH
~ R WR L ~ Ho BAT HORRNN SWITTCCHH

R 0-f-o FREE

N PUSH 0- 1-0

L 0- f-o COLOR BII WIG

I I I(CCOOLLOORR] Lbb Gr 00

STAARRTER SWWIITTCCHH

~ ST BAT

FREE

PUSH 0- ~

COLOR VIR BI

BRAKE LIGHT SWITCCHH STTAARRTTEERRSWITTCCHH
CONNECTORSS
FRONNTT

Disconnnneecctt the front brakee light switchh connector and
checkk for continuity betweenn the terminals.

There should bee continuity with the brake lever applied,
andd there shouulldd be no continuity with the brake lever is
releeaasseedd..

BRAAKKEE LIGHTT
SWITTCCHH

20-8 http://mototh.com

LIGHTS/METERS/SWITCHES

REAR

Removee the following:

-- driver seat (paggee 2-21)
-- fuel tank (pagee 5--33))
-- rear cowl (pagee 2--33))

Disconnect the rear brakkee light switch connector and check
for continuity betweeenn the terminals.

There should be continuity with the brakee pedal applied,
and there should bee no continuity with the brake pedaall is
releaseedd..

NEUTRAL INDIlCATTOORR/lSSWWIlTTCCHH NEUTRAL INDICATTOORR

INSPPEECCTTIIOONN

Make sure that the neutral indicator come on with the
ignition switch ONN and neutraall position.
If the indicator does not come on, inspect as follows:

Releasee the neutral switch connector from the clamp o f
the frame..
Disconnect the neutrall switch connector.

Shift the transmission into neutral and checckkfor continuity 20-9
between the Light green/RReedd wire terminal and ground.
There should be continuity with the transmission inn
neutral, and no continuity with the transmission inn gear
except neutra lI.

http://mototh.com

LIlGHTS//MMEETTEERRSS//SSWWIITTCCHHEESS
REMOVAL

Disconnect the neutral switch connneeccttoor (page 20--99\)..
Remove the drive sprocket cover.
Remove the bolt and neutral switch.

Removee the drive piece and spring.
Check the gear position switch for wear or damage.
Replace it if necessssaarryy..
Check the drive piece for wear or damagee..
Replace it if necesssaarryy..
CAUTION:
• Do not bent or tap the drivve piece whhenn instasll the drive

piece.
• Bent the driivve piece by forrccee or crush the coonnttaaccttpoint

will Cca/Juusee poorr electricity coonnnneeccttiioonn..

INSTALLATIONN

Instaallll the spring and drive pieccee..
Apply engine oil to the new O-ringg and installl it into the
groove of the neutraall switch.
Inssttaalll the neuttrraall switch to the crankkccaassee.

Tighhtteenn the boltt securreellyy..
Inssttaalll the remoovveedd parttss innthe revveerrsseeorder of removvaall..

20-1100 http://mototh.com

LLIIGGHHTTSS/MMEETTEERRSS/SSWWITCCHHEESS

FUEELL METERW/FUUEELL UNITT

FUUEELL METER INSPECCTTIIOONN

Removvee the fuell tank (paaggee 5--33)).
Disconnect the fueell unit 3PP connector.

Connect the jumper wire between the YellowlMWlhite and FUEL METER
Green wire terminals of the wire harness side..
Turn the ignition switcchh "ON"" and makkee sure that the fuel

meter needdllee swings to ""FFUULLL"N..

Connect the jumper wire betweeenn the BluelMWlhite and
Greenn wire terminals of the wire harnessss sidee..
Fueell meter iss inn good condition if the needlee returrnnss to
"EMPTYY""..

CAUTTIOONN::

0D0o not leave the termiinnaallss connnected withh the jumper
wirre for a long time, as it causseessdammaagaee to the fuelmeterr..

FUEL UUNNIT INSPECTIOONN

Disconnect the fuel unit 3P connectoorr.

Remove the four nuts and fuel unit. 20-1111
CAUTION.:
• Be carreffuull noott to damage the unitt cable.
• Be careffuull noott ttoo benntt the floatt aarrmm off the uniitt..

http://mototh.com

LLIGGHHTTSS//MMEETTEERRSS//SSWWIITTCCHHEESS

Measure the resistance betweeeenn the terminals as follows: .. -. ...
:(",.., / j
II IFULLL
I I566n0 EMPTY

Greeenn - BluelMWlhite 333 nR

Greeenn - YellowlMWlhite I 33nR I 56666Rn
IBlluueelWwhitee - YellowlMWlhite 60000Rn
I 60000Rn .0

FUUEELL UNITT I

Reconnnneeccttthe fuel uunniit 33P connector and turn the ignitioonn "--"'-

switch ON. .__----;::------------P..., \
Move the fuel uunniit float up and down andd makee sure that
the fuel gauge needle moves smoothly.

FLOAAT UUPP: Needdllee inn -"FFULL"-
FLOAAT DOWN:: Needdllee inn -"EEMMPPTTY-"

FFUUEELL UNNIITT

FUEELL UNIT INSTAALLLLAATTIIOONN

Insttaalll the new O-rinngg..
Insttaalll the fuel unit.

Insttaalll and tighten the four nuts.

20-12 http://mototh.com

LIGHTS/METERS/SWITCHESS

Routtee the fuel unit wire and connect the 3P connectoorr..
Installl the fuel tank (pagee 5-33))..

HORN I , .CONNECTORS

Disconnect the wire connectors from the horn.

Connect the battery voltage to the hornn terminals.

The horn is normal if it sounds when the battery connecteedd
across the horn terminals.

TURN SIGNAL RELAY

INSPPEECCTTIIOONN

Check the fcollowing:

-- battery condition

-- burned out bulb or non-specifiedd wattage
-- burned fuse

-- ignition switch and turn signal switch function

-- loose connectors

If above items all normal,, check the following:
Remove the rear cowl (page 2-3).
Disconnect the connector from the relay..

1. Short the White/Green and Gray terminals of the turn
signal relay connector with a jumpeerr wire. Check the
turn signal light by turning the switch "RR"" or "L".

i+ i+

Lights comes on Lights does not cocme on

ij +
• Brokeenn wire harnesss..

• Faulty turn signal relayy..
• Poor connectioonn of the connector.

http://mototh.com 20-13

LLlIGGHTS/MEETTEERS/SWITCHEESS

CCOOOOLLINNGG FFAANN MOTOR SWITCH

INSPPEECCTTIIOONN

Remoovvee the right middle ccoowwll (page 2-4)..

Faann motor ddooes not stop
Turn the ignitioonn switch OFF, disconnect the connector
fromm the fann motor switch and turn the ignition switch ONN
again.

If the fann motor does not stop, check for a shorted wire
betweeeenn the fan motor and switch.
If the fann motor stops, the fan motor switch is faulty.

Faann motor ddooess not start
Beforee testing, check for a blownn fan motor fuse (10AA))..
Warm upp the engine to operating temperature..

Disconnect the connector from the fan motor switch and
ground the connector terminal to the body ground.
Turnn the ignitioonn switch ON and check the fan motor.

IIf the motor starts, check the connectioonn at the fan motor
switch terminal. If it is OK, the fan motor switch is faulty.

If the motor does not start, removee the fuel tank (paggee 5-
4)) andd checkk for voltage betweenn the Bluee (+) and Green(-
) terminals at the fan motor switch 2P connector of the
maiinn harnesss side.

-- Battery voltaoge: Faulty fan motor
-- NNoo battery voltage: Open circuit or poor connectiioonn inn

Blue or Greeenn wire

REMMOVVAALLIAINNSSTTAALLLLAATTIOIONN

Draaiinn tthhee ccoooollaannt (page 6-5)..
Disconnect the fan motor switch connector and removvee
the fann motor switch.

Instaallll a new O-riinngg onto the switch.
Inssttaalll andd tighten the switch.

Connect the switch connector.
Fillll andd bleeedd the coolingg systemm (pagee 6-5))..

Instaallll the removeedd partss inn the reverse order of removaall..

20-14 http://mototh.com

LIGHTS/METERS/SWITCHES

COOLANTT TEMPERATURE GAUGGEE/! .r .
THERMOSENSOR
--~
- «~ ~• .-.SYSTEM INSPECTION

.' '" ~;/JI! .. _."Removee the fuel tank (pagee 5-33))..
•• •••

~ '. "P •....,. A' ". ,,'
~. ''. ~'. '~" ". . ~ . ~., <.~connector terminal to the body ground. .~ .
Disconnneecctt the thermosensor connector and ground the

I .I. ) " .• , .. ' ., . . .

..:41'' ~._.' .' .,'', .' '. ~...'... ~

Turn the ignition sWwiitch ONN and check the coolant ~: ~( ~\.:.-~ ~ CTEOMOPLEARNATTTUURREE
temperarute gauge needle. The needle should move to
"H".. ') GAUGE

CAUTION:: \: 3 21. "':::p~ ~ \ I

IImmmmeeddii8atteellyytuurmntheign"iittio"nsswwiittcchh OOFFFwhen" thhe "ntelteldlee
move to ""HH""(hhoott)) to prevent thhee gauuggee froomm ddammaaggiinngg..

-- If the needdllee moves, check the thermosseennssoorr..
-- If the needdllee does not move, checkk for open circuit in

Greeend/Blue wire.. If the Green/lBlue wire is OK, replaccee
the coolant temperature gauge.

http://mototh.com 20-15

LIGHTS/METERS/SWITCHES THERMOMETER

THERMOSENSOR INSPECTTIIOONN \A

PM@"'" THERMOOSSEENNSSOORR

Keep flammmaabbllee mateerials away fromm the eleccttrric heeaatt--
ing elemennt. Weeaarr protective clothingg, insuulated gloves
and eye protection.

Drainn tthhee ccoooollaant (page 66--5511..

Disconnect the thermosensor connector andd removvee the
thermosensor.

-Suspend the thermosensor inn a pann of coolant (500 - 50

mixturree)) on ann electric heatinngg element andd measure the
resistaannccee through the sensor as the coolant heatss up:

NOTE:
• Soak the thermosensor inn coolant up to its threads with

at least 40 mmm (1.577 inn))from the bottomm of the sensor.
• Keeepp temperature constant for 3 minutes beforee test-

ing. A suddenn change of temperature will result inn in--
correct readings. Doo not let the thermometer or
thermosensor touch the pan..

Temperature I I50°"CC (12222 O"FF) 120°"CC(24488 O"FF)
Reessiissttanccee
133.99--11778.a9.Q9 ~ 14.99--1177.3.Q3 ~

Reppllaaccee the sensor if it is out of specificaattiioonnss by moree
than 100 % at any temperature listedd..
Insttaallll the thermoseennssoorr..

Apply sealant to the thermosensor threads. DDoo not apply
sealant to the sensor headd..

Connect the thermosesor connector.

Filll andd bleeedd the cooling systemm (paggee 6-55))..

CLUTCCHH SWITCCHH

Disconnect the clutch switch connectors andd check for
continuiittyy..

There should be continuity with the clutcchh lever applied
andd no continuity with it releaseedd..

20-16 http://mototh.com

TACHO0MMEETTEERR LLlIGHTS/METERS/SWWIITTCCHHEESS

Disassseemmbbllee thee upppeerr cowwll (ppaaggee 22--55)).. GREE Wffl EAMINAL

Connect the commbbiinnaattiioonn mmeeter 99PP anndd tachometer 2PP
connneeccttoorr..

Chheecckkthe continuity beettwweeeennthee GGrreeeennwire termmiinnaall anndd
body ground.
There shoouulldd bbee conttinnuuiittyy..
If theree iss noo connttiinnuuiittyy,, check for oppeenn ciirrccuuiit inn thee GGrreeeenn
wirree..

Turnn thee iggnniittiioonn switch ONN andd mmeeaassuurree the voltage

beettwweeeennthe Whiitted/GGreen (+) andd Greeeenn(--1) wire terminalss..

There should bee battery voltage..
IIftthere iss noo voltage, check for openn circuit innWhite/Green
wire..

Start the engine andd measure the voltage betweeeenn the

Yellow/Green ((++I) andd Greeenn (--)).wire terminals.

There should bee at least 6V pulssee voltage..
If there is noo voltage, check the followinng:

- openn cicuit inn Yellow/Green wire
-- ignition contrrooll modulee (lICCMM))(paaggee 1188--66))

If there iss continuity andd ICCMM iss normal, replaccee the
tachometeerr..
For tachometeerr replacement, seee 20-5; combination meter
disassembllyy and assembly.

http://mototh.com 20-17

ROfT __ LUfT~ ~: _ _ __

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~~"~~~~§ ~M 0-

fm i~CcJ

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http://mototh.c

lilElllpl 21. WIRING DIAGRAM

0030Z-KPP-9000

com

22. TROUBLESHOOTING

~~ 22-1 PPOOR PPERFORMANCE AATT HHIGH 222-4
22-2 SPEED 22-4
ENGINE DOES NOT START OR IS
HARD TO START POOR HANDLING

ENGINE LACKS POWER 22-3

POOR PERFORMMAANNCCEEAATT LOW
AND IDLE SPEED

ENGINE DOES NOT START OR ISS HARD TOO START

Possible cause

-1. Check the fuel flow to carburetor - Not reaching - - - - i.~. • Clogged fuel line and fuel auto valve
I carburetor • Clogged fuel tank breathheerr

Reachhiinngg carburetor -Weak oOrr no spark - • Faulty spark plug

1t

2. Perform a spark test

• Fouledd spark plug

) • Faulty ignition control module (lICCMM))

• Brrokkeenn or shoorrtteedd sparrkk plluugg wire

Good spark • Faulty ignition switch

• Faulty ignition pulsee generatorr

j • Loosee or disconnected ignition
system wires

3. Remoovvee andd inspect spark pluugg ___ Wet plugg .. • Flooded carburetor

II • SSttaarrttiinngg eennrrichment ((SSEE)) vvaallve OONN

Gooodd positionn (oppeenn))

4. Start by fol/lowing noorrmmaall proceedduurree - • Throttle valve openn

I -• Air cleaner dirty

EEnngginee doess nott start EEnnggiinnee starts butt _ . Ilmproper chookkee operaationn
stooppss • Carburetor incoorrrreeccttllyy adjusted
j
• Intakkee pippee leaking
5. TTeesstt ccyylliinnddeerr ccoommpprreessssiioonn
• Impropeer ignition timiinngg (Faauullttyy ICCMM

or ignniittiioonn puullssee geenneerraattoorr))

• Fuueel\ contamminaateedd

-LLooww ccoommpprreessssiioonn - . VVaallvvee cclleeaarraannccee toooo ssmmaalll
• VVaallvvee sstuck ooppeenn

• WWoorrnn ccyylliinnddeerr aanndd ppiissttoonn rriinngg

• DDaammaaggeeddccyylliinnddeerr hheeaadd ggaasskkeett

• SSeeiizzeedd vaallvvee

• IImmpprrooppeer vvaallvvee timmiinngg

http://mototh.com 22-1

TRROOUUBBLLEESSHHOOOOTTIINNGG

ENNGGIINNEELACKSS POWWEERR

-11.. RRaaiissee whheeeell off thee ground anndd sppiinn bbyy - WWhheeeellss doo nnoott sppiinn - PPoossssiibbllee caauussee
• BBrraakkee dragging

hhaanndd freeellyy • WWoorrnn or dammaaggeedd wheeeell bbeeaarriinngg

I

Wheeel ppiinnss freeellyy -Preessssuurree low -----t.~. • Fauullttyy tire valve

•422.. Check tire pressure
I • Puncturedd tire

Pressssuurree normal -- • Cluttcchh slippinngg

t

33.. Accelerate rapiddllyy fromm low to second - Ennggiinnee speed

I doesn't channggee • Wornn clutcchh discs/plates

Enggiinnee speedd reduucceedd when clutcchh iss accordingly • Warped clutcchh discs/plates
Weak clutchh spring
releaasseedd whenn clutchh • Additive iinn enggiinnee oill

iss releeaasseedd • Startingg enrichment (SEE)) valve ONN
• positioonn (oppeenn))
t -4. Accelerate lightly - - - - - - - - - - Enggiinnee speeeedd does -
I not increassee

Enginnee speedd increase • Clogged air cleaner

1j • Restricted fuel flow
• Clogged muffler
• Pinchedd fuel tank breather
5.. Check ignition timing - - - - - - - - Incorreecctt - - - - . . . ,.*-. • Faulty ignition control module (ICCMM))

I • Faulty ignition pulse generator

Correct
4 -6.. Test cylinder compression - - - - - - Incorrreecctt
• Valve stuck open

I - - - - - Clogged • Worn cylinder and pistonn rings
• Lleeaakkiinngg cylinder head gasket
Norrmmaall Improper valve timing
-•
1 Carburetor not serviced frequentlyy
•--------<-~ enough
7. Check carburetor for clogging

I

Not cliogged
•t -8.. Remove spark plug - - - - - - - - - Fouled or - - - - - - • Plug not serviced frequently enough
I discolored • Spark plugg is the incorrect heat

Not fouled or discolored rangee

•t99. Check oil level and condition - - - - - lIncorrect - - - - - -*- . Oil level too high
II • Oil level too low
Correcctt • Contaminatedd oil
+ -10. Remove cylinder head cover and inspect - Valve train not - . Clogged oil passagee
lubrication lubricated • Clogged oil pummDp
properly
II

Valve tranin lubricated properly

22-2 http://mototh.com

TROUBBLLEESSHHOOOOTTIINNGG

1"1.. Check for engine overheating Overheat - - - - - - - i.~. • Coolant level too low
I
• Fan motor not working (Faulty fan
Not overheat
motor or fan motor switch)
\ • Excessive ccarbon bbuild-up iin

1, 22.. Accelerate or run at high speed combustion cchhamber
• Use ooff poor qquuaalliittyy ffuel
~ • Clutch ssllipppiingg
• Lean fuel mixture
Engine does not knock • Wrong type of fuel

- - - Engine knocks _ • Worn cylinder or piston

• Wrong type of fuel
• Excessive carbon build-up in

combustion chamber
• Ignition timing too advance (Faulty

ICM)
• Lean fuel mixture

POOR PERFORMANNCCEEAT LOWAND IDLE SPEED

Possiiblle cause

-,1.. Check carburetor pilot screw adjustment -- Incorrect - - - - -.-. • Seeeesectiioonn5
I
Correct

t Loose carburetor insulator bands
Damageedd carburetor insulator
2. Check for leakingg carburetor insulator - - Leaking *-----~.-. •
~

I•
Not leak

3. Perform spark test Weak or intermit- - • Faulty carbon or wet fouled spark
I tent spark plug

Good spark • Fouled spark plug
• Faulty ignition control module (lICCMM))
• Faulty ignitioonn coil
• Faulty alternator
• Broken or shorted spark plugg wire
• Faulty ignition pulsee generator

• Faulty ignitioonn switch
• Loosee or disconnecteedd ignition

system wires

1

4. Check ignition timing - - - - - - - - Incorrect - - - - - i._. • Improper ignition timing (faulty ICM)

i
Goooodd spark

http://mototh.com 2222--33